1 Tools

1. combination rip and crosscut pull saw

2. solid plastic angle square

3. combination Phillips and square drive screw driver

2 Supplies

1. combination Phillips and square drive screws

3 Step by Step Instructions

For tips and techniques to help yourself or your child be more successful with woodworking see woodworking_tips.htm

1) Measure and cut the bottom of the toolbox from the 1”x 6” wood. Sixteen inches accommodates a standard thirteen-inch hammer. Mark the length and draw a squared line with the rafter square. Cut the bottom board with the crosscut saw.

2) Use the cut edge of the bottom board to mark the length of the 1” x 4” end-piece. Draw the squared line and cut.

3) Clamp the 1” x 6” bottom board straight upright. Position the 1” x 4” end piece on it. Keep the two pieces square (the adult can hold the pieces square). Drill two pilot holes with the hand drill to prevent the wood from splitting. Mark the depth to drill on the drill bit with a piece of tape (about one inch). The depth should be shorter than the screw. The width of the drill bit should be less than the shaft of the screw. Drill the two pilot holes straight down and screw the screws in while checking that the two boards are square. The adult should hold the boards while the child screws it down so that the screw does not cause the boards to push apart. Repeat steps (2) and (3) for the other end of the bottom board.

4) Lay the assembled bottom and ends on the 1” x 4” board and mark the long sidepiece. Draw a square line and cut.

5) Put the sidepiece on top of the bottom and ends. Clamp in position. Drill pilot holes. Screw in the screws. Repeat steps (4) and (5) for the other side.

6) Cut two 1-foot long pieces of the 1” x 4” wood for the handle ends. Decide whether the box will be stackable or one box alone.

a) One box alone: The cross piece of the handle can be a 7/8” or 1” hardwood dowel or 1” x 2” wood.

i) Hardwood dowel handle: To drill holes for the dowel rod, use a brace and auger bit. Clamp the two handle end pieces securely and tighten across the holes to be drilled (this prevents splitting). Drill until the tip of the auger comes through the second board. Then flip the boards over and finish the hole from the other side. This prevents splintering when the auger exits the hole.

ii) 1”x2” cross piece: To cut slots for the 1” x 2” piece in the handle ends, use the end of the 1” x 2” to mark the ‘U’ slot to be cut. Remember the 1” x 2” is strong skinny side up so that is how it should be positioned. Clamp both pieces upright in the clamp. Cut down with the ripsaw. Use a coping saw to saw across the bottom.

iii) Flat tops or angled handle ends? Decide whether you would like the handle ends to be flat on top or angled down. Angled or curved corners can prevent jammed fingers when reaching for tools. But a flat top is nice for stacking other items on top of the toolbox (or another set of tool boxes!). Now is the time to saw the angle. To cut a diagonal line clamp the line to be cut straight upright and use the rip saw to saw straight down. To saw a curve use the coping saw. Keep in mind that the handle will be screwed or nailed into the handle ends so leave enough room around the notch or hole for the nail or screw.

iv) Assembling the handle: Mark the center of each end of the box on the bottom. Mark the center of the handle ends on the bottom. Line up the centers and clamp a handle end piece onto the end of the box. Drill two pilot holes into the bottom corners with the twist drill and screw in the screws. Repeat for the other handle-end. Put the dowel rod or 1” x 2” handle in position. Mark and cut it. Thread the dowel rod through one hole. Put wood glue on both ends of the dowel rod. Put the dowel rod through the last hole and tap a finishing nail into each end through the top. If a 1”x 2” handle is used put glue in the notches and drive finishing nails at an angle from the top. You are done!

b) Two stackable boxes: The cross piece will be a 1” x 2” length of wood. The one-foot 1”x4” should be notched in the corner as follows. Hold the end of the 1” x 2” wood on the corner of the 1”x4” piece and mark it the ‘L’. Remember the 1”x4” piece is strong with the skinny side up. Clamp the two pieces together in the vice upright. Cut down with the ripsaw. Clamp the two pieces sideways in the vice. Cut down with the crosscut saw. Mark the center of the bottom of the toolbox and draw and squared line up the side. Position a side-piece of the handle just next to the center line and with the handle notch facing center. Clamp, drill two pilot holes and put the screws in. Repeat for the other side. Place the 1” x 2” across the notches, mark the length and cut. Drill a pilot hole through the 1”x2” and into the handle end pieces. Dab wood glue between the wood and screw the 1”x2” on. Repeat at the other end. You are done with one toolbox!

c) The second box: A second stackable toolbox is the same as the first except for these differences. The bottom should be ½ inch shorter. The handle ends should be minus the height of the first toolbox. The notches of the handle ends will face the center from the other direction.

Toolbox Plan - Copyright 2001 Kids Can Make It, Inc. All rights reserved